Resin bonded composite articles and process for fabrication thereof

Abstract

A preconsolidated tape of continuous, high strength filaments in a metal matrix is coated with a layer of adhesive polymer and cut into shaped plies. The coated plies are stacked in a mold and resin bonded together by the application of heat and pressure. Many of the desirable physical properties of a diffusion bonded metal matrix article are also found in the resin bonded metal matrix article of the subject invention. Also, the use of preconsolidated adhesive coated plies eliminates the need for high diffusion bonding pressures and temperatures, thereby cutting the time involved for the bonding and molding operation by a factor of 8 in some instances.

Having thus described typical embodiments of our invention, that which we claim as new and desire to secure by Letters Patent of the United States is: 
     
       1. A process for manufacturing a composite monolayer tape material of high strength, high modulus filaments in a metal matrix for use in the fabrication of a multilayer tape, composite article comprising the steps of: positioning a plurality of high strength, high modulus reinforcing filaments parallel to each other and substantially uniformly spaced apart on a layer of metal foil, said filaments being aligned along the tensile axis of the tape material;   depositing a plasma spray layer of metal matrix material over said filaments to bond the filaments to the metal foil layer and to each other;   positioning an additional metal foil layer over the filaments and plasma sprayed matrix material;   consolidating the combination of foil layers, filaments, and plasma sprayed matrix material by the application of heat and pressure thereto until the matrix material is fully densified thus forming a consolidated, monolayer tape;   cleaning at least one side of said consolidated tape; and   applying a layer of adhesive polymer immediately after said step of cleaning to a cleaned side of said tape, the adhesive polymer being selected from the group consisting of a liquid resin, an unsupported layer of thermoplastic resin, a thermoplastic resin supported in a medium of fibrous material, and thermosetting resin supported in a medium of fibrous material.   
     
     
       2. The process according to claim 1 wherein the filaments are selected from the group consisting of boron filaments and boron filaments coated with silicon carbide, and the foil material is selected from the group consisting of aluminum and alloys of aluminum. 
     
     
       3. The process according to claim 2 wherein the adhesive polymer is a film forming thermoplastic high temperature polyimide melt adhesive having the characteristic that its adhesive properties do not deteriorate with time upon exposure to air such that the tape has a long shelf life.